Additive manufacturing powder particle, method for treating the additive manufacturing powder particle, and method for additive manufacturing

Patent metadata

Field	Value
Publication number	US-12017404-B2
Application number	US-202318173188-A
Country	US
Kind code	B2
Filing date	Feb 23, 2023
Priority date	Jun 3, 2019
Publication date	Jun 25, 2024
Grant date	Jun 25, 2024

Abstract

An additive manufacturing powder particle including a surface and at least one functional group formed on the surface, wherein the at least one functional group increases laser energy absorption of the additive manufacturing powder particle. The additive manufacturing particle is treated with plasma radiation to form hydroxyl functional groups on a surface of the additive manufacturing powder particle, where the hydroxyl functional groups have a molecular vibrational frequency corresponding to a laser wavenumber range of laser energy of an additive manufacturing process, and where the plasma radiation treating the additive manufacturing powder particles depends on the laser energy of the additive manufacturing process. Treating the additive manufacturing powder particle with the plasma radiation increases laser energy absorption of the additive manufacturing powder particle when the additive manufacturing particle is exposed to the laser energy, produced by a carbon dioxide laser, of the additive manufacturing process.

First claim

What is claimed is:

1. An additive manufacturing powder particle comprising:
a surface; and
at least one functional group formed on the surface, wherein the at least one functional group increases laser energy absorption of the additive manufacturing powder particle;
wherein:
the additive manufacturing particle is treated with plasma radiation to form hydroxyl functional groups on a surface of the additive manufacturing powder particle, where the hydroxyl functional groups have a molecular vibrational frequency corresponding to a laser wavenumber range of laser energy of an additive manufacturing process, and where the plasma radiation treating the additive manufacturing powder particles depends on the laser energy of the additive manufacturing process; and
treating the additive manufacturing powder particle with the plasma radiation increases laser energy absorption of the additive manufacturing powder particle when the additive manufacturing particle is exposed to the laser energy, produced by a carbon dioxide laser, of the additive manufacturing process.

2. The additive manufacturing powder particle of claim 1 , wherein the at least one functional group increases laser energy absorption of the additive manufacturing powder particle for a laser having a predetermined wavelength.

3. The additive manufacturing powder particle of claim 1 , wherein the at least one functional group includes one or more of oxygen functional groups, carboxyl functional groups, hydroxyl functional groups, ester functional groups, and ether functional groups.

4. The additive manufacturing powder particle of claim 1 , further comprising a metallic core.

5. The additive manufacturing powder particle of claim 1 , further comprising a ceramic core.

6. The additive manufacturing powder particle of claim 1 , comprising a diameter of about 10-200 microns.

7. The additive manufacturing powder particle of claim 1 , wherein the at least one functional group increases a surface tension of the surface relative to another surface without the at least one functional group, where the other surface has a similar material composition to the surface.

8. The additive manufacturing powder particle of claim 1 , wherein the additive manufacturing powder particles are one of: polymer powder particles, polymer-coated metal powder particles, ceramic powder particles, or polymer-coated ceramic powder particles.

9. The additive manufacturing powder particle of claim 1 , wherein the additive manufacturing powder particles are polymer powder particles or polymer-coated metal powder particles.

10. The additive manufacturing powder particle of claim 1 , wherein the additive manufacturing powder particles are ceramic powder particles.

11. The additive manufacturing powder particle of claim 1 , wherein the additive manufacturing powder particles are polymer-coated ceramic powder particles.

12. A method for additive manufacturing using the additive manufacturing particle of claim 1 , the method comprising:
treating the additive manufacturing powder particle with plasma radiation;
exposing the treated additive manufacturing powder particle to the laser energy of the additive manufacturing process, where treating the additive manufacturing powder particles with the plasma radiation increases laser energy absorption of the additive manufacturing powder particles;
forming, with the plasma radiation, functional groups on the surface of the additive manufacturing powder particle with the plasma radiation, where the hydroxyl functional groups have a molecular vibrational frequency corresponding to a laser wavenumber range of the laser energy of the additive manufacturing process; and
producing the laser energy with the carbon dioxide laser, wherein treating the additive manufacturing powder particles with the plasma radiation forms the hydroxyl functional groups on the surface of the additive manufacturing powder particle;
wherein the plasma radiation treating the additive manufacturing powder particles depends on the laser energy of the additive manufacturing process.

13. The method of claim 12 , wherein the additive manufacturing powder particles are agitated by the mechanical vibrator, the sonic vibrator, or the fluid agitation so that an entire surface of the respective additive manufacturing powder particles is exposed to the plasma radiation.

14. The method of claim 12 , wherein treating the additive manufacturing powder particles with the plasma radiation forms one or more of oxygen functional groups, carboxyl functional groups, hydroxyl functional groups, ester functional groups, and ether functional groups on surfaces of the additive manufacturing powder particles.

15. The method of claim 12 , wherein the additive manufacturing process is a selective laser sintering additive manufacturing process.

16. A method for treating the additive manufacturing powder particle of claim 1 , the method comprising:
exposing the additive manufacturing powder particle to the plasma radiation, where the plasma radiation forms the hydroxyl functional groups, on the surface of the additive manufacturing powder particle, having molecular bonds that vibrate in response to irradiation by the laser energy of the additive manufacturing process; and
physically changing the orientation of the additive manufacturing particle so that the additive manufacturing powder particle moves to expose different portions of the surface to the plasma radiation.

17. The method of claim 16 , wherein the plasma radiation is selected so as to form the functional groups depending on a predetermined laser wavenumber range of the laser energy.

18. The method of claim 16 , wherein a ratio of a portion of each additive manufacturing powder particle, in a plurality of the additive manufacturing powder particle, having functional groups formed on a respective surface of the additive manufacturing powder particle to a portion of the additive manufacturing powder particle not exposed to the plasma radiation is about 0.001.

19. The method of claim 16 , wherein the plasma radiation is selected so as to form hydroxyl functional groups, on the surfaces, that have molecular bonds that vibrate in response to irradiation by the carbon dioxide laser.

20. The method of claim 16 , wherein the plasma radiation forms one or more of oxygen functional groups, carboxyl functional groups, ester functional groups, hydroxyl functional groups, and ether functional groups.

Assignees

• Boeing Co

Inventors

• Sinha Nishant Kumar
• Prakash Om

Classifications

• B22F1/102

  Metallic powder coated with organic material · CPC title

• B22F1/145

  Chemical treatment, e.g. passivation or decarburisation · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• B33Y40/00

  Auxiliary operations or equipment, e.g. for material handling · CPC title